Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B28—WORKING CEMENT, CLAY, OR STONE
  • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
  • B28B7/00—Moulds; Cores; Mandrels
  • B28B7/34—Moulds, cores, or mandrels of special material, e.g. destructible materials
  • B28B7/346—Manufacture of moulds
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
  • B22D19/00—Casting in, on, or around objects which form part of the product
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
  • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
  • B22F10/20—Direct sintering or melting
  • B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
  • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
  • B22F5/003—Articles made for being fractured or separated into parts
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
  • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
  • B22F5/007—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of moulds
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B28—WORKING CEMENT, CLAY, OR STONE
  • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
  • B28B1/00—Producing shaped prefabricated articles from the material
  • B28B1/001—Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B28—WORKING CEMENT, CLAY, OR STONE
  • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
  • B28B1/00—Producing shaped prefabricated articles from the material
  • B28B1/24—Producing shaped prefabricated articles from the material by injection moulding
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B33—ADDITIVE MANUFACTURING TECHNOLOGY
  • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
  • B33Y10/00—Processes of additive manufacturing
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B33—ADDITIVE MANUFACTURING TECHNOLOGY
  • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
  • B33Y80/00—Products made by additive manufacturing
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
  • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
  • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
  • F01D5/12—Blades
  • F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
  • F01D5/284—Selection of ceramic materials
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22C—FOUNDRY MOULDING
  • B22C9/00—Moulds or cores; Moulding processes
  • B22C9/02—Sand moulds or like moulds for shaped castings
  • B22C9/04—Use of lost patterns
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
  • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
  • B22F10/60—Treatment of workpieces or articles after build-up
  • B22F10/66—Treatment of workpieces or articles after build-up by mechanical means
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
  • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
  • F05D2230/00—Manufacture
  • F05D2230/20—Manufacture essentially without removing material
  • F05D2230/21—Manufacture essentially without removing material by casting
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
  • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
  • F05D2300/00—Materials; Properties thereof
  • F05D2300/20—Oxide or non-oxide ceramics
  • F05D2300/21—Oxide ceramics
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
  • Y02P10/00—Technologies related to metal processing
  • Y02P10/25—Process efficiency

Definitions

• the present invention relates to a method for manufacturing a ceramic turbine blade.
• Turbine blades in particular those of aircraft turbine engines, must meet multiple requirements. In particular, they must be able to withstand very high temperatures, exceeding 1600K, and have complex shapes allied to a high accuracy which therefore requires low manufacturing tolerances.
• the metals can not withstand temperature gradients of the aforementioned order without deformation, it is necessary to provide the metal blades of internal cooling systems, which are complex and expensive.
• the ceramic is not easily machinable, it is difficult, with a ceramic-based material, to obtain the desired complex shapes, with the necessary precision, according to an industrial process.
• US Patent 5,028,362 is concerned with the manufacture of ceramic parts according to a gel casting process. According to this method, a ceramic-based suspension is cast in a mold and then polymerized. This patent evokes the possibility of obtaining pieces of complex shapes with this technique. However, the geometry of the pieces that are thus manufactured is dictated by the geometry of the mold. Thus, if the manufacture of the mold does not obey extremely strict constraints in terms of manufacturing tolerances requiring precise and expensive machining, the shape of the parts obtained from this mold may not be sufficiently precise for particularly demanding applications, such as turbine engine turbines.
• the invention aims at providing a method for manufacturing a ceramic turbine blade that is substantially free of the aforementioned drawbacks and which, in particular, allows the manufacture, on an industrial scale, of a ceramic blade with a complex and very precise geometry .
• This object is achieved by the fact that, in order to manufacture a ceramic turbine blade, a selective powder bed melting technique is used to obtain a blade cavity in a mold, a ceramic-based suspension is provided. This suspension is introduced into the blade cavity, a step is performed to gel the suspension in the cavity to obtain a blade that can be extracted from the cavity and the said blade is extracted from the cavity.
• the blade cavity can be obtained with a complex and very precise geometry.
• the mold having this impression can then be used industrially to manufacture turbine blades by casting a ceramic-based suspension.
• the blades thus obtained present rigorously the same geometry as the blade cavity which, as we have seen, is very precise. It is thus possible to manufacture turbine blades that are resistant to very high temperature gradients, according to complex and very precise geometries, without the need to implement expensive cooling or shape-rectification technologies.
• the mold is made directly by selective melting on a powder bed.
• the mold can be directly manufactured in one piece within which the blade cavity is defined in the hollow.
• this part can be cut into at least two mold parts, for example by a wire cutting technique (using a wire in which a current is passed through) or a laser cutting technique of large size. precision (using a laser beam).
• These mold parts can be joined to form the impression between them, or separated for demolding the blade formed in this impression.
• the impression is formed with very high precision and can have complex shapes required for a turbine blade.
• a blade model is produced by selective melting on a bed of powder, a polymer-based paste is cast around this blade model, said die paste is cured.
• the mold block is cut to obtain at least two mold parts enclosing the blade model, and said parts are separated to extract the blade model from the mold block, so that said parts can be reunited again to form the blade impression between them.
• the blade model which is made by selective melting on a powder bed and this model is used to manufacture the mold by forming the blade cavity in the mold, and the ceramic blade can then be made in this mold. Since the mold is made of a polymer-based paste which is hardened on the blade model, it fits very exactly the shape of this model, so that the geometry of the blade cavity thus obtained in the mold is very precise.
• the mold being made of polymer-based material, it can be cut to form the mold parts, using a laser cutting technique or a wire cutting technique, as mentioned above.
• the blade is dried.
• the blade is sintered.
• the ceramic base of the suspension is silicon nitride.
• FIG. 1 illustrates the manufacture of a mold by selective melting on the powder lite
• FIG. 2 shows a mold made by selective melting on a powder bed, with a blade imprint
• Figure 3 shows the mold of Figure 2, cut into two parts, the two parts being open;
• FIG. 5 illustrates the manufacture of a mold block from a blade model made by selective melting on a powder bed
• FIG. 6 shows the mold block cut in two parts, the blade model being secured to one of these parts.
• FIG. 2 shows a mold 10 in the form of a parallelepiped block, with a blade cavity 12 inside this block.
• This mold was manufactured by selective melting on a powder bed.
• selective melting or selective sintering of powder beds is carried out by a high energy beam, in particular a laser beam or an electron beam.
• a high energy beam in particular a laser beam or an electron beam.
• a material 1 is provided in the form of powder particles, of which a first layer C1 is deposited on a support 2 and this first layer is selectively scanned by the beam 3 of high energy, so that to melt the powder precisely according to the path of the beam on the first layer, so that the molten powder forms, by its substantially instantaneous solidification, a first mold solid layer 10A.
• a multiplicity of layers of material 1 is successively deposited on the first one and each layer is subjected to a new scanning of the bundle so as to form successive layers and the powder which is not removed is removed. melted, until the block shown in Figure 1.
• the material is initially contained in a chamber 5, the bottom 5A rises as and when the successive layers, so that the doctor blade 4 can scrape progressively the powder material to bring it into the adjacent chamber 6, above the support 2 which decreases as and when the construction of successive layers.
• the powder used is, for example, a powder based on Nylon®, wax or metal, in particular a nickel-based alloy.
• the type of beam and its power are chosen according to the powder retained.
• the mold is manufactured in one piece, with the blade cavity negative in its central portion.
• it is then cut along the cutting line 14 to form two mold parts, 11A and 11B, visible in FIG. 3, each having a blade half-cavity, 13A. and 13B.
• the mold has a pouring channel 15, formed for example in two respective parts 15A and 15B on each of the mold parts, to allow the introduction of the molding material of the blade into the mold, when its two parts are united.
• Nylon® or a metal powder, for example a nickel-based superalloy will be favored for the material of the powder subjected to the selective melting process.
• the wax type materials will be favored to make a lost mold, which is broken to unmold the blade formed in the impression.
• a ceramic-based suspension is produced, in particular silicon nitride.
• ceramic particles are mixed with a binder, a dispersant and water.
• the binder is a curable resin, preferably a monomer or a glycol. It has the function, during gelling and drying of the suspension, after its injection or pouring into the mold, to agglomerate the ceramic particles in solid mass.
• the dispersant is, for example, an ammonium polyacrylate. Its function is to keep the ceramic particles suspended in the water before drying.
• a curing precursor is added to the suspension, to ensure crosslinking of the binder.
• the suspension in the form of slurry suspension, is introduced into the blade cavity inside the mold. Under the effect of the curing precursor, the pasty suspension gels, until a sufficiently solid blade (green body) to be extracted from the mold. Just after the injection or casting of the suspension in the mold, the mold is degassed to eliminate any air bubbles in the suspension, before its substantial gelation.
• the semi-solid blade is dried and then sintered.
• the second embodiment of the invention is a blade model 20 which is manufactured by selective melting on a bed of powder, according to the technique described above.
• the material used for the selective melting powder can be a Nylon®, wax or metal-based powder, and the beam type and its power are chosen according to the powder retained.
• the blade model 20 is placed in a chamber 22 and a polymer-based paste 24 is cast around this blade model.
• This paste is in particular a silicone-based polymer such as polydimethylsiloxane (PDMS). It also contains a crosslinking precursor which causes a hardening of the mold around the blade model.
• PDMS polydimethylsiloxane
• the mold is cut to obtain two (or more) mold portions 21A and 21B. These two parts can be separated as can be seen in FIG. 6 to allow the extraction of the blade model 20.
• two (or more) mold parts are obtained which can be joined together. forming the blade cavity 12 between them, as the two mold parts of Figure 3 form between them the blade impression when they are joined.
• Parallel to the cutting of the mold block there is provided a casting channel or injection, for example in two parts 25A and 25B, respectively made on each of the two mold parts 21A and 21B.
• the blade may be molded from a ceramic base suspension as described with reference to the first embodiment.
• the semi-solid blade (green body) can then be extracted from the mold, then dried and sintered as in the first embodiment.
• suspension used in both embodiments to form the blade can be obtained as follows (the given values are used to determine the proportions).
• Silicon nitride-based ceramic powder for example of the type marketed under the reference Syalon® 050, is used.
• Syalon® 050 dispersion dispersant Dispex® A-40, which is dispersant to base of ammonium polyacrylate.
• Small amounts of Syalon® 050 powder are successively added and the grinding is activated between each addition.
• this precursor is bis (3-aminopropyl) amine.
• the amount of hardening precursor is such that the ratio resin / precursor curing, expressed by mass, is 1 / 0.23. This gives a suspension ready to be cast in the mold in which is formed the blade cavity.
• the suspension is injected into the mold, for example a PDMS mold obtained according to the first or second embodiment of the invention, and the mold is then degassed to eliminate the air bubbles.
• the gelling process then begins at room temperature, of the order of 18 ° C to 22 ° C.
• the blade has sufficiently solidified to form a semi-solid blade or green body, which can be demolded.
• the mold is then demolded either by breaking the mold or, being a reusable mold, by removing its different mold parts.
• the semi-solid blade is transferred to an oven, where it is subjected to a temperature of the order of 40 ° C for a sufficient time (for example of the order of 24 hours) for complete drying of the blade. Once dried, the blade is sintered.

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• 2014
  • 2014-11-04 FR FR1402492A patent/FR3027840B1/fr active Active
• 2015
  • 2015-11-03 BR BR112017009311A patent/BR112017009311A2/pt not_active Application Discontinuation
  • 2015-11-03 RU RU2017119200A patent/RU2017119200A/ru not_active Application Discontinuation
  • 2015-11-03 WO PCT/FR2015/052953 patent/WO2016071619A1/fr active Application Filing
  • 2015-11-03 CN CN201580065707.3A patent/CN107000246A/zh active Pending
  • 2015-11-03 US US15/524,166 patent/US20170361490A1/en not_active Abandoned
  • 2015-11-03 EP EP15798534.2A patent/EP3215328A1/fr not_active Withdrawn

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